Magnetocaloric refrigerator

ABSTRACT

The invention is for an apparatus and method for a refrigerator and a heat pump based on the magnetocaloric effect (MCE) offering a simpler, lighter, robust, more compact, environmentally compatible, and energy efficient alternative to traditional vapor-compression devices. The subject magnetocaloric apparatus alternately exposes a suitable magnetocaloric material to strong and weak magnetic field while switching heat to and from the material by a mechanical commutator using a thin layer of suitable thermal interface fluid to enhance heat transfer. The invention may be practiced with multiple magnetocaloric stages to attain large differences in temperature. Key applications include thermal management of electronics, as well as industrial and home refrigeration, heating, and air conditioning. The invention offers a simpler, lighter, compact, and robust apparatus compared to magnetocaloric devices of prior art. Furthermore, the invention may be run in reverse as a thermodynamic engine, receiving low-level heat and producing mechanical energy.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from U.S. provisional patentapplication U.S. Ser. No. 61/397,246, filed on Jun. 7, 2010 and entitled“Magneto-Caloric Refrigerator” and from U.S. provisional patentapplication U.S. Ser. No. 61/397,175, filed on Jun. 7, 2010 and entitled“Staged Magneto-Caloric Refrigerator,” the entire contents of all ofwhich are hereby expressly incorporated by reference.

FIELD OF THE INVENTION

This invention relates generally to magnetocaloric machines and morespecifically to heat pumps based on magnetocaloric effect.

BACKGROUND OF THE INVENTION

The subject invention is an apparatus and method for magneto-caloricrefrigerator (MCR) offering improved energy efficiency, and reducedemissions of pollutants and greenhouse gases.

According to the U.S. Department of Energy, refrigeration and airconditioning in buildings, industry, and transportation may account forapproximately 10¹⁹ joules of yearly primary energy consumption in theU.S.A. Air conditioning is also a major contributor to electric utilitypeak loads, which incur high generation costs while generally usinginefficient and polluting generation turbines. In addition, peak loadsdue to air conditioning may be a major factor in poor grid reliability.Most of the conventional air conditioning, heat pumps, and refrigeratorsmay achieve cooling through a mechanical vapor compression cycle. Thethermodynamic efficiency of the vapor compression cycle is today muchless than the theoretical maximum, yet dramatic future improvements inefficiency are unlikely. In addition, the hydrofluorocarbon refrigerantsused by vapor compression cycle today are deemed to be strongcontributors to the green house effect. Hence, there is a strong needfor innovative approaches to cooling with high efficiencies and net-zerodirect green house gas emissions.

The magneto-caloric effect (MCE) describes the conversion of amagnetically induced entropy change in a material to the evolution orabsorption of heat, with a corresponding rise or decrease intemperature. In particular, MCE material may heat up when it is immersedin magnetic field and it may cool down when removed from the magneticfield.

All magnetic materials, to a greater or lesser degree, may exhibit anMCE. However, some materials, by virtue of a unique electronic structureor physical nanostructure, may display a significantly enhanced MCE,which may potentially be harnessed for technological application. Incontrast to the MCE found in paramagnetic materials, the large MCEexhibited by ferromagnetic materials near their magnetic phasetransition temperature (also known as the Curie temperature or Curriepoint) may render them suitable as working materials for magneticcooling at the target temperatures appropriate for commercial,industrial, and home refrigeration application and heat pump devices,namely 200 to 400 degrees Kelvin. For example, gadolinium (Gd) is aferromagnetic material known to exhibit a significant MCE near its Curiepoint of about 293 degrees Kelvin. In recent years, a variety of otherMCE materials potentially suitable for operation at near roomtemperature have been discovered. See, for example, “Chapter 4:Magnetocaloric Refrigeration at Ambient Temperature,” by Ekkes Bruck in“Handbook of Magnetic Materials,” edited by K. H. J. Buschow, publishedby Elsevier B.V., Amsterdam, Netherlands, in 2008.

One of the very promising novel MCE materials is the intermetalliccompound series based on the composition Gd₅(Si_(x)Ge_(1-x))₄, where0.1≦x.1≦0.5, disclosed by K. A. Gschneider and V. K. Pecharsky in U.S.Pat. No. 5,743,095 issued on Apr. 28, 1998 and entitled “Active MagneticRefrigerants based on Gd—Si—Ge Materials and Refrigeration Apparatus andProcess,” which is hereby incorporated by reference in its entirety. Seealso and article by V. K. Pecharsky and K. A. Gschneider, “TunableMagnetic Refrigerator Alloys with a Giant Magnetocaloric Effect forMagnetic Refrigeration from ˜20 to ˜290K,” published in Applied PhysicsLetters, volume 70, Jun. 16, 1997, starting on page 3299. MCE producedby this family of compounds, also referred to as GdSiGe, has beenlabeled as “giant” because of its relatively large magnitude (reportedas 4 to 6 degrees C. per Tesla of magnetic flux density). In particular,the MCE of the GdSiGe alloys may be reversible. Another noteworthycharacteristic of the GdSiGe family is that the Curie temperature, maybe tuned with compositional variation. This feature allows the workingtemperature of the magnetic refrigerator to vary from 30 degrees Kelvinto 276 degrees Kelvin, and possibly higher, by adjusting the Si:Geratio. For the purpose of this disclosure, an MCE material is defined asa suitable material exhibiting a significant MCE.

A magneto-caloric refrigerator (MCR) is a refrigerator based on MCE. MCRoffers a relatively simple and robust alternative to traditionalvapor-compression cycle refrigeration systems. MCR devices may havereduced mechanical vibrations, compact size, and lightweight. Inaddition, the theoretical thermodynamic efficiency of MCR may be muchhigher than for a vapor compression cycle and it may approach the Carnotefficiency. An MCR may employ an MCE material (sometimes referred to asa magnetic refrigerant working material) that may act as both as a“coolant” producing refrigeration and a “regenerator” heating a suitableheat transfer fluid. When the MCE material is subjected to strongmagnetic field, its magnetic entropy may be reduced, and the energyreleased in the process may heat the material. With the MCE material inmagnetized condition, a first stream of heat transfer fluid directedinto a thermal contact with the MCE material may be warmed in theprocess and the heat may be carried away by the flow. When substantialportion of the heat is removed from the MCE material, the fluid flow maybe terminated. As the next step, the magnetic field may be reduced,which may cause an increase in magnetic entropy. As a result, the MCEmaterial may cool. A second stream of heat transfer fluid may bedirected into a thermal contact with the MCE material where may depositsome of its heat and it may be cooled in the process. When substantialportion of the heat is deposited into the MCE material, the fluid flowmay be terminated. Repeating the above steps may result in asemi-continuous operation. One disadvantage of such an MCR is the needfor multiple flow loops typically involving pumps, heat exchangers, andsignificant plumbing.

Despite the apparent conceptual simplicity, there are significantchallenges to the development of a practical MCR suitable for commercialapplications. This is in-part due to the relatively modest temperaturechanges (typically few degrees Kelvin per Tesla of magnetic fluxdensity) of the MCE material undergoing MCE transition. In addition, atpresent time the magnetic field produced by permanent magnets is limitedto about 1.5 Tesla maximum. As a result, an MCR using permanent magnetsand a single step MCE process may produce only a few degrees Kelvintemperature differential. Many important practical applications such ascommercial refrigeration and air conditioning may require substantiallyhigher temperature differentials, typically 30 degrees Kelvin andhigher.

One approach to achieving commercially desirable temperaturedifferentials from MCR may use multiple MCR stages (also known ascascades). Heat flow between stages may be managed by heat switches.Each stage contains a suitable MCE material undergoing magnetocalorictransition at a slightly different temperature. While the temperaturedifferential achieved by one stage may be only a few degrees Kelvin, theaggregate operation of multiple stages may produce very largetemperature differentials. See, for example, “Thermodynamics of MagneticRefrigeration” by A. Kitanovski, P. W. Egolf, in International Journalof Refrigeration, volume 29 pages 3-21 published in 2006 by ElsevierLtd., the entire contents of which are hereby expressly incorporated byreference.

A variety of heat switching approaches have been proposed but none haswon commercial acceptance. For example, Ghoshal, in U.S. Pat. No.6,588,216 entitled “Apparatus and methods for performing switching inmagnetic refrigeration systems,” issued on Jul. 8, 2003, andincorporated herein by reference in its entirety, discloses switching ofthermal path between MCR stages by mechanical means usingmicro-electro-mechanical systems (MEMS), and/or electronic means usingthermoelectric elements. Ghoshal's thermal path switching by MEMS isinherently limited by the poor thermal conductivity of bare mechanicalcontacts. Ghoshal's thermoelectric switches have very limitedthermodynamic efficiency which substantially increases the heat load tothe MCR and reduces the overall MCR efficiency.

In summary, there is a need for 1) reducing or eliminating moving partsand pumped fluid loops in MCR systems, 2) simpler and more reliable MCRoperation, and 3) means for attaining commercially desirable temperaturedifferentials from MCR. A specific need exists for reliable, low-thermalresistance means for switching of the heat flow to and from the MCEmaterial in staged (cascaded) MCR.

SUMMARY OF THE INVENTION

The present invention provides a magneto-caloric refrigerator (MCR)having one or more stages. The MCR of the subject invention may use MCEmaterial formed as one or more members alternately exposed to strong andweak magnetic field. Exposure to magnetic field may be coordinated byswitching of heat to and from the MCE material by heat commutatorscomprising a thermally conductive core. Thermal communication betweenthe MCE material and the thermally conductive cores is facilitated by athin layer of suitable thermal interface fluid (TIF) locatedtherebetween. In particular, an MCE material immersed in a weak magneticfield is arranged to be in a good thermal communication with a thermallyconductive core of the heat commutator operating at a lower temperature,and an MCE material immersed in a strong magnetic field is arranged tobe in a good thermal communication with a thermally conductive core of acommutator operating at a higher temperature.

More specifically, in accordance with one preferred embodiment of thesubject invention, the MCR comprises a suitable MCE material formed asone or more annular disks (MCE rings), heat commutators formed as two ormore annular disks, and a thermal interface fluid (TIF). The commutatorsare arranged generally equally spaced on a common axis and affixed inspace. The disks of MCE material are placed each between adjacentcommutators, arranged to be concentric therewith, and affixed to acommon shaft arranged to rotate about them their axis of symmetry. Theaxial gap between adjacent disks and commutators is arranged to be verysmall, typically on the order of about 50 to about 500 micrometers, andit is filled with the TIF. The commutator comprises a thermallyconductive core, thermally insulating portions, and one or morepermanent magnets. The permanent magnet in each commutator is arrangedto have its magnetization vector generally parallel to the commutatoraxis of rotational symmetry. The commutators are clocked about theircommon axis so that their permanent magnets are placed at the sameazimuthal position and their magnetization vectors at that position arepointing in the same direction. In particular, the magnets are arrangedso that an MCE disk rotating between adjacent commutators would becyclically exposed to a sequence of relatively low magnetic field,increasing magnetic field, strong magnetic field, and decreasingmagnetic field. For example, a given portion of an MCE disk may beimmersed a stronger magnetic field when it is between the magnets, andit may be immersed a weaker magnetic field when it is away from themagnets.

For the purposes of this disclosure, the term “strong magnetic field” isdefined as a magnetic field having an absolute value of magnetic fluxdensity of at least 0.3 Tesla (3,000 Gauss), and the term “weak magneticfield” is defined as a magnetic field having an absolute value ofmagnetic flux density of at least 0.1 Tesla (1,000 Gauss) lower than the“strong magnetic field” flux density. In particular, the range of weakmagnetic field may include magnetic flux density of essentially zero (0)Tesla (i.e., no field).

In operation, the shaft is arranged to rotate about its axis, thusrotating the MCE disks between the stationary commutators. Rotary motionmay cause the TIF layer in the gaps between adjacent MCE disks andcommutator to flow in a regime known as a shear flow and also known as aCouette flow. Rotary motion may cyclically expose a given portion of anMCE disk to a sequence of relatively low magnetic field, increasingmagnetic field, strong magnetic field, and decreasing magnetic field. Asa result, a given portion of an MCE disk may cyclically undergo relativewarming and relative cooling due to MCE.

In a single stage MCR in accordance with the subject invention, an MCEdisk has a first planar surface adjacent to a first heat commutator witha first small axial gap therebetween and a second planar surfaceadjacent to a second heat commutator with a second small axial gaptherebetween. Said first gap and said second gap are each filled with asuitable TIF. The thermally insulating portion of the first commutatoris arranged to be in a contact via TIF with a portion of the MCE diskimmersed in an increasing magnetic field, strong magnetic field, anddecreasing magnetic field. The thermally conductive core of the firstcommutator is arranged to be in a good thermal contact by means of TIFwith a portion of the MCE disk immersed a weak magnetic field. Note thatthe terms “by means of” and “via” may be used interchangeably in thisdisclosure. The thermally conductive core of the second commutator isarranged to be adjacent to and in a good thermal contact via TIF with aportion of the MCE disk immersed in a strong magnetic field. Thethermally insulating portion of the second commutator is arranged to beadjacent to and in a contact with a portion of the MCE disk immersed ina decreasing magnetic field, weak magnetic field, and increasingmagnetic field. As a result, the first commutator may be in a goodthermal contact with a cooler portion (or portions) of the MCE diskwhile the second commutator may be in a good thermal contact with awarmer portion (or portions) of the MCE disk. Hence the rotation of theMCE disk causes the first commutator to become cooler and the secondcommutator to become warmer. By connecting the thermally conductive coreof the first commutator to a heat load (a heat reservoir at a lowertemperature) and the thermally conductive core of the second commutatorto a heat sink (a heat reservoir at a higher temperature), the MCR maypump heat from the heat load to the heat sink.

In a multiple stage MCR in accordance with the subject invention, heatmay be transported from one adjacent MCE disk to another through ashared commutator located between them. In particular, the thermallyconducting core of the shared commutator is arranged to be in a goodthermal contact via TIF with a portion of a lower stage (generallycooler) MCE disk immersed in a strong magnetic field and simultaneouslyin a good thermal contact via TIF with a portion of an adjacent higherstage (generally wanner) MCE disk immersed in a weak magnetic field.

The thermal interface fluid (TIF) is a key material for facilitatingefficient heat transfer in the MCR of the subject invention. For thepurpose of this disclosure, TIF may be a liquid or a paste. Preferably,suitable TIF has a good thermal conductivity, surface wettingcapability, lubrication properties, low melting point, acceptably lowviscosity, low or no toxicity, and low cost. The inventor has determinedthat TIF should preferably have a thermal conductivity of at least as 1W/m-degree K and most preferably at least 3 W/m-degree K. In someembodiments of the invention the TIF may be a liquid metal. Suitableliquid metal may be an alloy of gallium (Ga) such as a non-toxiceutectic ternary alloy known as galinstan and disclosed in the U.S. Pat.No. 5,800,060. Galinstan (68.5% gallium, 21.5% indium, and 10% tin) isreported to have thermal conductivity of about 16 W/m-degree K (about 27times higher than water), a melting point of minus 19 degreesCentigrade, low viscosity, and excellent wetting properties. Brandeburget al. in the U.S. Pat. No. 7,726,972 discloses a quaternary galliumalloy having a melting point of minus 36 degrees Centigrade, which maybe also suitable for use with the subject invention. Other suitablegallium alloys may include those disclosed in the U.S. Pat. No.5,792,236.

In other embodiments of the invention the TIF may also comprise a fluidcontaining nanometer-sized particles (nanoparticles) also known asnanofluid. Nanofluids are engineered colloidal suspensions ofnanoparticles in a base fluid. The nanoparticles used in nanofluids maybe typically made of metals, oxides, carbides, carbon, graphite,graphene, graphite nanotubes, or carbon nanotubes. Common base fluidsmay include water, alcohol, and ethylene glycol. Nanofluids may exhibitenhanced thermal conductivity and enhanced convective heat transfercoefficient compared to the base fluid alone. In yet other embodimentsof the invention the TIF may not be strictly a fluid but rather a pastecomprising mainly of micro-scale and/or nano-scale particles made ofhigh thermal conductivity materials such as silver, copper, or graphitein suitable base liquid or paste.

Accordingly, it is an object of the present invention to provide an MCRthat is relatively simple and robust alternative to traditionalvapor-compression cycle refrigeration systems, while attainingcomparable or even higher thermodynamic efficiency.

It is another object of the invention to provide an MCR for generalrefrigeration and air conditioning while improving energy efficiency andreducing emissions of pollutants and greenhouse gases.

It is yet another object of the invention to provide an MCR having oneor more stages to achieve commercially useful temperature differentials.

It is still another object of the subject invention to provide an MCRhaving low mechanical vibrations, compact size, and lightweight coupledwith a thermodynamic efficiency exceeding that of thermo-electriccoolers.

It is a further object of the subject invention to provide efficientswitching of heat to and from an MCE material.

These and other objects of the present invention will become apparentupon a reading of the following specification and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of the SMCR apparatus of the subjectinvention.

FIG. 2 is a cross-sectional view 2-2 of the SMCR apparatus shown in FIG.1.

FIG. 3 is an isometric view of the SMCR apparatus of FIG. 1 with apartial section exposing selected internal features.

FIG. 4 is an exploded view of the SMCR apparatus of FIG. 1 omittingcertain repeated components.

FIG. 5 is an enlarged view of portion 5 of FIG. 2.

FIG. 6 is an enlarged portion 6 of FIG. 5.

FIG. 7A is an isometric view of the MCE disk.

FIG. 7B is a cross-sectional view 7B-7B of the MCE disk of FIG. 7A.

FIG. 8A is an isometric view of the heat commutator with one side facingup.

FIG. 8B is an isometric view of the heat commutator of FIG. 8A with thereverse side facing up.

FIG. 8C is an isometric view of the commutator of FIG. 8A with a partialsection exposing selected internal features.

FIG. 9A is a cross-sectional view 9A-9A of the heat commutator of FIG.8A.

FIG. 9B is a cross-sectional view 9B-9B of the heat commutator of FIG.9A.

FIG. 10A is an isometric view of the thermally conductive core with oneside facing up.

FIG. 10B is an isometric view of the thermally conductive core of FIG.10A with the reverse side facing up.

FIG. 10C is an isometric view of the thermally conductive core of FIG.10A with a partial section exposing selected internal features.

FIG. 11 is a cross-sectional view 11-11 of the commutator of FIG. 10A.

FIG. 12A is an isometric view of the permanent magnets and the yokes ofthe SMCR of FIG. 1 with all other components removed from the view.

FIG. 12B is an isometric view of the permanent magnets and the yokes ofFIG. 12A rotated 45 degrees clockwise to expose obstructed elements.

FIG. 13A is an isometric view of an alternative permanent magnet.

FIG. 13B is an isometric view of another alternative permanent magnet.

FIG. 14 is an isometric view of the MCE disk of FIG. 7A indicatingregions exposed to specific magnetic field strength.

FIG. 15 is a plot of absolute magnetic field flux density along theheavy broken curve 118 of FIG. 14.

FIG. 16 is a cross-sectional view of a portion of the MCR of FIG. 1.

FIG. 17 is a diagram of temperature versus entropy illustrating athermodynamic cycle of an exemplary portion of one MCE disk of FIG. 16.

FIG. 18 is a cross-sectional view of a portion of the MCR of FIG. 1showing alternative heat commutators.

FIG. 19A is an isometric view of an alternative thermally conductivecore with the reverse side facing up.

FIG. 19B is an isometric view of an alternative thermally conductivecore of FIG. 19A with the reverse side facing up.

FIG. 20A is a view of an alternative MCE ring for reduced parasitic heatflow in azimuthal direction.

FIG. 20B is a cross-sectional view 20B-20B of the alternative MCE ringof FIG. 20A.

FIG. 21A is a view of another alternative MCE disk having portions madeof material having high thermal conductivity.

FIG. 21B is an enlarged view of portion 21B of the another alternativeMCE ring of FIG. 21A.

FIG. 21C is an enlarged cross-sectional view 21C-21C of FIG. 21B.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Selected embodiments of the present invention will now be explained withreference to drawings. In the drawings, identical components areprovided with identical reference symbols in one or more of the figures.It will be apparent to those skilled in the art from this disclosurethat the following descriptions of the embodiments of the presentinvention are merely exemplary in nature and are in no way intended tolimit the invention, its application, or uses.

Referring now to FIGS. 1, 2, 3, and 4, there is shown an MCR apparatus100 in accordance with one preferred embodiment of the presentinvention. Note that the isometric view of FIG. 3 having a partialsection is formed from the view in FIG. 1 by removing the quadrant-likevolume identified in FIG. 1 by a broken line 122. The MCR apparatus 100has six (6) stages and it comprises six (6) MCE disks 154, seven (7)heat commutators 160, five (5) spacer disks 172, six (6) spacer rings176, four (4) magnetic flux returns 148, end caps 168 and 170, two (2)bearings 138, a drive shaft 158, and an enclosure shell 134.

Referring now to FIGS. 2, 3, and 4, the enclosure 134 may be a roundtubular member. The heat commutators 160 may be generally formed asannular disks (FIG. 4) arranged equally spaced on a common axis andfixed with respect to the enclosure shell 134. Spacing of the heatcommutators 160 may be defined by the spacer rings 176 which may be alsofixed with respect to the enclosure shell 134. The MCE disks 154 may beplaced to interspace the heat commutators 160, arranged to be concentrictherewith, and positioned on the drive shaft 158. In particular, thehexagonal hole 174 (FIG. 4) of the hub 156 of the MCE disk 154 mayslidingly engage the hexagonal surface 140 of the drive shaft 158. Axialposition of the MCE disks 154 on the drive shaft 158 may be maintainedby spacer disks 172 interspacing the MCE disks 154. The hexagonal hole166 (FIG. 4) of the spacer disk 172 may slidingly engage the hexagonalsurface 140 of the drive shaft 158. The drive shaft 158 may be rotatablysuspended in the bearings 138 installed in the end caps 168 and 170.O-rings 178 (FIGS. 2 and 3) may be installed on the shaft 158 to provideseals. The end caps 168 and 170 may include o-rings 150 (FIGS. 2 and 3)to provide seals to the enclosure shell 134. The heat commutators 160comprise permanent magnets 146 (FIGS. 2 and 3). The magnetic fluxreturns 148 may be installed on the end caps 168 and 170 to reduce thereluctance of the magnetic circuit formed by the permanent magnets 146.

Referring now to FIG. 5, the spacer disks 172 are sized to provide aradial clearance gap 182 between the outside diameter of the spacerdisks 172 and the inside diameter of the heat commutators 160. Referringnow to FIG. 6, the clearance space “S” between adjacent commutators 160a and 160 a, and the thickness “T” of the MCE disk 154 are chosen sothat the width “G” of axial gaps 184 between MCE disk 154 and heatcommutators 160 a and 160 a is preferably between about 50 micrometersand about 500 micrometers (about 2 thousands of an inch and about 20thousands of an inch). Generally, the width “G” may be adjusted byappropriately defining the height “H” of the spacer rings 176. Inaddition, the outside diameter of the MCE disk 154 is set to provide aradial clearance gap 198 between the perimeter of the MCE disk 154 andthe spacer ring 176. Preferably, the MCE disk 154 is axially positionedabout half way between the permanent magnets 146 (FIG. 6) in adjacentheat commutators 160 a and 160 a to balance the magnetic forces ofattraction. The gaps 182, 184, and 198 should be arranged to ensure thatthe shaft 158 together with the MCE disks 154 and the spacer disks 172can freely rotate on the bearings 138 while preventing the MCE disks 154and the spacer disks 172 from rubbing on the heat commutators 160 a and160 a and on the spacer rings 176. The gaps 182, 184, 198 are filledwith a suitable thermal interface fluid (TIF) 142. A list of exemplaryTIF that may be suitable for practicing with the MCR 100 has beenprovided above.

Note that choosing a small width “G” of the gap 184 may beneficiallyimprove thermal communication between the MCE disk 154 and the heatcommutators 160 a and 160 a, but the manufacturing tolerances of the MCR100 may become more challenging. Conversely, choosing a large width “G”of the gap 184 may beneficially relax manufacturing tolerances of theMCR 100 at the expense of reduced thermal communication between the MCEdisk 154 and the heat commutators 160 a and 160 a.

If the TIF 146 comprises gallium and its alloys, metal components of theMCR 100 may require protective coating to prevent corrosion. Metalcomponents requiring anti-corrosion coating may include portions the MCEdisk 154, portions of the commutators 160, and the end caps 168 and 170.Suitable protective coatings may include but they are not limited totitanium nitride (TiN) and the diamond-like coating (DLC) Titankote C11available from Richter Precision, Inc. in East Petersburg, Pa.

The shaft 158, enclosure shell 134, spacer disks 172, spacer rings 176,and MCE disk hubs 156 (FIG. 4) are preferably made from a materialhaving very low thermal conductivity. Such suitable materials mayinclude, but they are not limited to, epoxies including fiberglass epoxyand graphite epoxy, glass fiber silicons, plastics includingpolyvinylchloride (PVC), polystyrene, polyethylene, acrylics, Teflon®,and ceramics. In addition, some of these parts (namely, the drive shaft158) may be made hollow to further reduce their thermal conductance.Furthermore, the outer perimeter of the enclosure shell 134 may beequipped with a suitable thermally insulating jacket (not shown).Suitable thermally insulating jacket may be made from, but it is notlimited to, polystyrene foam.

The bearings 138 are preferably made of made from a material having lowfriction with respect to the material of the shaft. Alternatively, thebearings 138 may include antifriction (i.e., rolling element) bearingportion. The o-rings 150 and 178 may be made from a suitable elastomericmaterial such as buna-n, silicon rubber, Viton®, or Teflon®. The endcaps 168 and 170 are preferably made of made from a material having highthermal conductivity such as, but not limited to, copper, aluminum,silicon, silicon carbide, and aluminum nitride. The magnetic fluxreturns 148 are preferably made from a soft magnetic material having ahigh magnetic saturation such as, but not limited to, mild steel, lowcarbon steel, silicon steel, iron, iron-cobalt-vanadium alloys,Consumet® electrical iron, and Hyperco® 50. Consumet® electrical ironand Hyperco® 50 are available from Carpenter Technology Corporation inWyomissing, Pa.

Referring now to FIGS. 7A and 7B, the MCE disk 154 comprises an MCE ring162 and a hub 156. The MCE ring 162 may be formed from a suitable MCEmaterial and it may be shaped as an annular disk having an outsidediameter “D”, width “W”, and thickness “T”. Typical range for theoutside diameter “D” is from about 5 centimeters to about 30centimeters, however, an MCE ring 162 having a diameter “D” outside thisrange may be also practiced. Typical range for the width “W” is fromabout 2 centimeters to about 12 centimeters, however, an MCE ring 162having a width “D” outside this range may be also practiced. Typicalrange for the thickness “T” is from about 0.5 millimeters to about 5millimeters, however, an MCE ring 162 having a thickness “T” outsidethis range may be also practiced. Preferably, the MCE material of eachMCE ring 162 is optimized for the anticipated operating temperaturerange in accordance with its placement in the MCR 100. For example, ifthe MCE rings 162 are made of the above noted GdSiGe alloy, the Si:Geratio may be adjusted so that the alloy Currie point is near (or within)the anticipated operating temperature range of the MCE ring. The hub 156is affixed to the MCE ring 162. The hub 156 has a hexagonal hole 174 forengaging the hexagonal surface 140 of the drive shaft 158. When the hub156 is made of thermoplastic material, it may be molded directly ontothe MCE ring 162.

Referring now to FIGS. 8A, 8B, 8C, 9A, and 9B, the heat commutator 160may be generally formed as an annular disk comprising a thermallyconducting core 164, thermally insulating portions 151, 152, and 153,and permanent magnets 146. Note that the isometric view of FIG. 8Chaving a partial section is formed from the view in FIG. 8A by removingthe quadrant-like volume identified in FIG. 8A by a heavy broken line.The thermally conducting core 164 shown in FIGS. 10A, 10B, 10C, and 11may be generally formed as an annular disk-like member comprisingthermal interface surfaces 192 and 194, sloped surfaces 143 and 144, andmagnet pockets 180. Note that the isometric view of FIG. 10C having apartial section is formed from the view in FIG. 10A by removing thequadrant-like volume identified in FIG. 10A by a heavy broken line. Thethermally conducting core 164 is preferably constructed from a materialhaving high thermal conductivity. Materials suitable for construction ofthe thermally conducting core 164 may include, but they are not limitedto, copper, aluminum, silicon, aluminum nitride, and silicon carbide.The thermally conducting core 164 may be fabricated as one piece usingcasting, conventional machining, molding, or electro-discharge machining(EDM), or any combination thereof, or by any other suitable technique.The insulating portions 151, 152, and 153 (FIGS. 8A, 8B, 8C, 9A, and9B,) of the heat commutator 160 are preferably made from a materialhaving a low thermal conductivity and/or being substantially thermallyinsulating. When the insulating portions 151, 152, and 153 are made of asuitable thermoplastic material, they may be molded directly onto thethermally conductive core 164. The permanent magnets 146 may beinstalled in the pockets 180 within the thermally conducting core 164(see FIGS. 10A, 10B, 10C, and 11) prior to installation of theinsulating portion 153. Preferably, the insulating portions 153 seal themagnets 146 in their pockets 180 to prevent their exposure to the TIF.The permanent magnets 146 may be of the rare earth type such as aneodymium-iron-boron (NdFeB) composition having a remanent magnetic fluxdensity in excess of 1.4 Tesla, but other types of permanent magnets maybe also practiced with the subject invention. Preferably, the permanentmagnets 146 are arranged to fit tightly into the pockets 180 to providegood thermal communication therebetween. The magnetization vectors 186of the permanent magnets 146 are preferably arranged to be perpendicularto the thermal interface surfaces 194 of the thermally conducting core164 (FIG. 10B). The direction of the magnetization vectors 186 isgenerally shown in FIG. 9B where the symbol “•” represents amagnetization vector being normal to the drawing sheet and pointing outtoward the viewer, and the symbol “®” represents a magnetization vectorbeing normal to the drawing sheet and pointing in away from the viewer.

When the commutators 160 are installed in the MCR 100 as shown in FIGS.2, 3, and 4, the magnetization vectors of their permanent magnets 146 ateach azimuthal position are aligned in the same direction. As a result,the permanent magnets 146 and the four (4) flux returns 148 form amagnetic structure 126 shown in FIGS. 12A and 12B. The magnets 146 inthe magnetic structure 126 are arranged in four stacks 120 a, 120 b, 120c, and 120 d. The magnets in each stack have their magnetization vectors186 aligned in the same direction. Furthermore, the magnetizationvectors 186 of the permanent magnets 146 in the stacks 120 a and 120 care pointing in the same direction. The magnetization vectors 186 of thepermanent magnets 146 in the stacks 120 b and 120 d are pointing in thesame direction, which is opposite to the direction of magnetizationvectors of the stacks 120 a and 120 c. Two (2) magnetic flux returns 148are provided to close the magnetic circuit 190 (FIG. 12A) formed by themagnet stacks 120 a and 120 c. Another two (2) magnetic flux returns 148are provided to close the magnetic circuit formed by the magnet stacks120 b and 120 d.

The permanent magnets 146 shown in FIGS. 12A and 12B are formed to arectilinear shape. However, other magnet shapes may be also used withthe subject invention. FIGS. 13A and B respectively show examples ofalternative permanent magnet shapes 146′ and 146″ that may be used withthe subject invention.

An MCE disk 154 installed in the MCR 100 will be exposed magnetic fieldspatially varying from weak to strong. FIG. 14 is an approximate map ofthe magnetic field in the MCE disk 154 identifying regions 130 ofgenerally constant and strong magnetic field, regions 128 of generallyconstant and weak magnetic field, and regions 132 of increasing ordecreasing magnetic field having strong gradient. FIG. 15 shows atypical profile of absolute magnetic field value along an azimuthal path118 in the MCE ring 162 of FIG. 14. Azimuthal positions I, II, III, andIV generally define boundaries between regions of specific magneticfield strength. In particular, the segment IV⁻-I is generally a regionof a weak magnetic field, the segment I-II is generally a region of anincreasing magnetic field, the segment II-III is generally a region of astrong magnetic field, the segment III-IV is generally a region ofdecreasing magnetic field, and the segment IV-I⁺ is generally a regionof a weak magnetic field. FIG. 16 shows an enlarged section of the MCR100 along an azimuthal path (which may be similar to the path 118 ofFIG. 14) including two MCE disks 154 a and 154 b, and their adjacentheat commutators 160 a, 160 b, and 160 c. The azimuthal positions I, II,III, and IV are shown with respect to the features of the heatcommutators 160 a, 160 b, and 160 c.

In operation, the drive shaft 158 together with the MCE disks 154 anddisk spacers 172 (FIG. 2) may be rotated by an externally applied torquein the direction identified by arrow 116 (FIG. 1). For example, thedrive shaft may 158 may be rotated by an electric motor, hydraulicmotor, air motor, an internal combustion engine, a mechanical spring, byhand, or by any other suitable means. Concurrently, the heat commutators160, the enclosure shell 134, the spacer rings 176, the bearings 138,the end caps 168 and 170, and the magnet flux returns 148 may remainstationary. The relative motion between the MCE disks 154 and the heatcommutators 160 may cause the TIF 142 in the gaps 184 (FIGS. 6 and 16)to flow in a regime known as “shear-driven flow” also known as a“Couette flow.” Such a flowing condition of the TIF 142 maysignificantly enhance its heat transferring capability.

Now referring to FIG. 16, rotary motion causes the MCE rings 162 a and162 b to move azimuthally in the direction of the arrow 124. Thus anexemplary portion of the MCE rings 162 a and 162 b may repeatedly passthrough the positions IV⁻, I, II, III, IV, and I. In particular, theexemplary portion of the MCE ring 162 a arriving at the position IV⁻forms a good thermal communication (via TIF 142 in the gap 184) with thethermally conducting core 164 a of the heat commutator 160 a. Whilebeing in the segment IV⁻-I (region of substantially constant weakmagnetic field), the exemplary portion of the MCE ring 162 a may be inits lower temperature state and it may receive heat from the thermallyconducting core 164 a. In particular, heat flow is indicated by a dottedline and arrow 114. Concurrently, the exemplary portion of the MCE ring162 a is thermally insulated from the heat commutator 160 b by theinsulating portion 152 b. Since most MCE materials may have a limitedthermal conductivity (typically around 10 Watts/meter-degrees Kelvin orless), azimuthal conduction of heat in the MCE ring 162 a may be ratherslow compared to the speed of azimuthal motion indicated by the arrow124. Hence, the temperature of the exemplary portion of the MCE ring 162a at the position I may be higher than its temperature at the positionIV⁻. The associated thermodynamic process is shown in FIG. 17, which (inan idealized theoretical sense) plots the temperature of the exemplaryportion of the MCE ring 162 a against its entropy. In particular, thethermodynamic process of the exemplary portion of the MCE ring 162 a inthe segment IV-I, which is labeled “isofield heating” (because it occursat a substantially constant magnetic field) includes heat input (fromthe thermally conducting core 164 a) accompanied by the increases ineach the temperature and the entropy the exemplary portion.

Referring now back to FIG. 16, the exemplary portion of the MCE ring 162a may now progress to the segment I-II (a region of increasing magneticfield) where it may experience a temperature rise due to the MCE.Concurrently, the exemplary portion of the MCE ring 162 a is beingthermally insulated from the thermally conducting core 164 a by theinsulating portion 151 a and from the thermally conducting core 164 b bythe insulating portion 152 b. The thermodynamic process of the exemplaryportion of the MCE ring 162 a in the segment I-II is labeled “adiabaticheating” in FIG. 17 because the heating occurs under substantiallythermally insulated conditions. Referring now back to FIG. 16, theexemplary portion of the MCE ring 162 a may now progress to the segmentII-III (a region of substantially constant strong magnetic field) whereit may be in a good thermal communication (via TIF 142 in the gap 184)with the thermally conducting core 164 b of the heat commutator 160 bwhile being thermally insulated from the thermally conducting core 164 aby the insulating portion 151 a. Note, that at least a portion the heatacquired by the exemplary portion of the MCE ring 162 a in the segmentIV⁻-I has been substantially transported to the segment II-III by themotion of the MCE ring 162 a. Heat transport is indicated by the dottedline 114. A portion of the heat stored in the exemplary portion of theMCE ring 162 a may be now transferred via TIF 142 into the thermallyconducting core 164 b of the heat commutator 160 b. The thermodynamicprocess of the exemplary portion of the MCE ring 162 a in the segmentII-III is labeled “isofield cooling” because it occurs at asubstantially constant (and strong) magnetic field. This processincludes heat loss (to the heat commutator 160 b) accompanied bydecreases in each the temperature and the entropy of the exemplaryportion of the MCE ring 162 a.

Referring now back to FIG. 16, the exemplary portion of the MCE ring 162a may now progress to the segment III-IV (a region of decreasingmagnetic field) where it may experience a temperature decrease due tothe MCE. Concurrently, the exemplary portion of the MCE ring 162 a isbeing thermally insulated from thermally conducting core 164 a of theheat commutator 160 a by the insulating portion 151 a, and fromthermally conducting core 164 b of the heat commutator 160 b by theinsulating portion 152 b. The thermodynamic process of the exemplaryportion of the MCE ring 162 a in the segment III-IV is labeled“adiabatic cooling” in FIG. 17 because the cooling occurs undersubstantially thermally insulated conditions. As the exemplary portionof the MCE ring 162 a arrives at the position IV, its theoreticalthermodynamic state may be same as it was at the position IV⁻, thuscompleting a closed thermodynamic cycle. Thus the, position IV marksboth the end of the above described cycle and the beginning of a newcycle. As the exemplary portion of the MCE ring 162 a progresses thoughthe segment IV-I⁺, it acquires heat from the thermally conducting core164 a and so on. Because the MCE ring 162 a has to pass through four (4)peaks and four (4) valleys in the absolute magnetic field, it willexperience four thermodynamic cycles per rotation. Each such a cycle mayremove heat from the thermally conducting core 164 a of heat commutator160 a and “pump” it to the thermally conducting core 164 b of the heatcommutator 160 b. Thus, the net effect of the rotation of the MCE ring162 a is the removal of heat from the heat commutator 160 a and“pumping” it to the heat commutator 160 b. Concurrently, a similarprocess takes place on the MCE ring 162 b, namely heat removal from theheat commutator 160 b and “pumping” it to the heat commutator 160 c. Thethermodynamic cycle of the MCE ring 162 b may be similar to that shownin FIG. 17, but it may generally occur at an elevated temperature. EachMCE disk 154 (with its MCE ring 162) represents a stage in the MCR 100,which is shown in FIGS. 2 and 3 to have six (6) stages. With additionalMCE disks 154 and commutators 160 being added, an MCR with arbitrarynumber of stages may be constructed to attain a desirable temperaturedifferential. Similarly, the number of peaks and valleys in the absolutemagnetic field experienced by the MCE disks 154 in a single rotation maybe increased or decreased.

Referring now to FIG. 2, the end cap 170 is arranged to be in a goodthermal communication with its adjacent heat commutator, and the end cap168 is arranged to be in a good thermal communication with its adjacentheat commutator. Operation of the MCR 100 may cause the end cap 170 tobecome colder and the end cap 168 to become warmer. The end cap 170 maybe placed in a thermal communication with an article or a substance tobe cooled, while the end cap 168 may be placed in a thermalcommunication with a suitable heat sink. The number of MCE disks 154 andheat commutators 160 in the MCR 100 may be set in accordance with adesirable temperature differential between the “hot” end cap 168 and the“cold” end cap 170. The diameter of the MCE disk 154 may be increased toincrease the refrigeration power. A larger MCE disk diameter may alsomake it possible to increase the number of peaks and valleys in theabsolute magnetic field experienced by the MCE disks 154 in a singlerotation to further increase the refrigeration power. Using strongermagnets may also substantially increase the refrigeration power. Varyingthe speed of rotation may be also used to vary the refrigeration power,however, excessively slow speed of rotation may increase parasiticlosses due to heat conduction in azimuthal direction inside the MCE ring162, while excessively fast speed of rotation may limit the amount ofheat that may be conductively transferred between the interior and thesurface of the MCE ring 162. The latter may be due to the already notedrather limited thermal conductivity of the MCE material of the MCE ring162. Depending on a specific construction, the speed at which the MCRdrive shaft 158 may rotate for optimum performance may be in the rangeof several revolutions per minute (RPM) to several tens (10's) of RPM.As a result, the MCR of the subject invention may generate substantiallyless acoustic noise in the audible range than a comparable vaporcompression cycle refrigerator, which may have a compressor operating ataround 1800 RPM.

For example, if the MCR of the subject invention is used in arefrigerator or a freezer application, the “cold” end cap 170 may beplaced in a good thermal communication with an inside wall of arefrigerator/freezer and/or with air inside the refrigerator/freezer,while the “hot” end cap 168 may be placed in a good thermalcommunication with a suitable heat exchanger cooled by ambient air.

As another example, if the MCR of the subject invention is used in anair conditioning application, the “cold” end cap 170 may be placed in agood thermal communication with a heat exchanger thermally contactingthe ambient inside (indoors) air, while the “hot” end cap 168 may beplaced in a good thermal communication with a suitable heat exchangercooled by ambient outside air. Alternatively, if the MCR of the subjectinvention is used in a heat pump application, the “cold” end cap 170 maybe placed in a good thermal communication with a heat exchangerthermally contacting the ambient outside air, while the “hot” end cap168 may be placed in a good thermal communication with a suitable heatexchanger thermally contacting the ambient inside (indoors) air.

As yet another example, if the MCR of the subject invention is used inelectronics cooling application, the “cold” end cap 170 may be placed ina good thermal communication with the electronics to be cooled, whilethe “hot” end cap 168 may be placed in a thermal communication with asuitable heat exchanger cooled by ambient outside air. If the MCR of thesubject invention is used to cool electronics on a spacecraft, the “hot”end cap 168 may be placed in a good thermal communication with asuitable heat radiator.

In stationary applications, such as air conditioning of buildings, thedrive shaft 158 may be rotated by an electric motor, preferably througha reduction gear box. In mobile applications such as automotivevehicles, the drive shaft 158 may be rotated directly by the propulsionengine or motor. Furthermore, in some vehicular applications the driveshaft 158 may be rotated at least intermittently by mechanical energyrecovered during vehicle deceleration. Since the MCR of the subjectinvention may offer higher efficiency over a conventional vaporcompression cycle, it may be advantageously used for cabin airconditioning and comfort heating in electric vehicles and hybridelectric vehicles. Because cabin air conditioning and comfort heating insuch vehicles competes with propulsion motors for electric energy forbatteries, energy efficient air conditioning and heating is veryimportant.

Referring now to FIG. 18, there is shown an azimuthal section (similarto the section shown in FIG. 16) through a portion of an MCR of thesubject invention showing an alternative heat commutators 260 havingalternative thermally conducting cores 264 divided by insulators 257 atazimuthal position “A” and by insulators 255 and 259 at azimuthalposition “B”. The alternative thermally conducting core 264 may beformed by radially splitting the heat transfer surfaces 192 and 194 ofthe thermally conducting core 164 (FIGS. 10A and 10B) into heat transfersurfaces 292′ and 292″, and 294′ and 294″ respectively as indicated byheavy broken lines 212 in FIGS. 19A and 19B. In particular, thealternative thermally conducting core 264 may be formed as severalseparate portions rather than being monolithic.

The alternative thermally conducting core 264 allows for its separateportions to operate at different temperatures. For example, thealternative thermally conducting core 264 allows for a dedicated thermalcommunication between the portion of the MCE ring 162 a in the segmentII-B with the portion of the MCE ring 162 b in the segment A-I withoutbeing in a direct thermal communication via the thermally conductingcore material with the portion of the MCE ring 162 a in the segmentB-III. As another example, the alternative thermally conducting core 264allows, for a dedicated thermal communication between the portion of theMCE ring 162 a in the segment B-III with the portion of the MCE ring 162b in the segment IV-A without being in a direct thermal communicationvia the thermally conducting core material with the portion of the MCEring 162 b in the segment A-I⁺.

The preferential path for transporting the heat in the MCR of thesubject invention are shown as dotted lines and arrows 214 in FIG. 18.Whereas a monolithic thermally conducting core 164 is substantiallyisothermal during the operation of the MCR of the subject invention,portions the alternative thermally conducting core 264 may operate attemperatures different from each other. The permanent magnets 246 may bethermally insulated from portions of the thermally conducting core 264.MCR of the subject invention using alternative thermally conducting core264 may have a significant performance advantage over the MCR of thesubject invention using a monolithic thermally conducting core 164.

It has been noted above that heat conduction within the MCE ring 162 inthe azimuthal direction may be undesirable as it may reduce theefficiency of the MCR 100. FIG. 20A shows an alternative MCE ring 362having radial slots 369 for restricting parasitic flow of heat inazimuthal direction. The slots 369 may be empty or filled with asuitable thermally insulating material. FIG. 20B is a cross-sectionalview of the MCE ring 362 showing that the slots 369 may penetratethrough the full thickness of the MCE ring material. An alternativeslots (not shown) may not be necessarily radial and/or may notnecessarily penetrate through the full thickness of the MCE ringmaterial.

It has been noted above that MCE materials may have only a limitedthermal conductivity in the range of about 10 Watts/meter-degree Kelvinand often lower. This makes it challenging to conduct heat to and fromthe interior of the MCE ring 162. FIG. 21A shows another alternative MCEring 462 having portions 461 made of suitable MCE material and portions489 (FIGS. 21B and 21C) made of material having high thermalconductivity. For example, portions 489 may be made of copper, silver,aluminum, graphite, graphite fiber, graphene, or other suitablematerial. The transverse dimension “X” of portions 489 is preferablymade comparable to or smaller than the thickness “T” of the MCE ring462. Portions 489 may be formed as a cylinder, prism, parallel-piped,cones, or pyramids, or other suitable shapes. Portions 489 may enhancethe conductive heat transfer between the interior of the MCE material ofthe MCE ring 462 and the flat surfaces of the MCE ring 462, thusmitigating the limited thermal conductivity of typical MCE materials.This may beneficially allow for a substantial increase of the thickness“T” of the MCE ring 462, and/or substantial increase of the speed ofrotation of the MCE ring 462. In either case, an increased refrigerationpower may be obtained.

The above description of the embodiments of the present invention aremerely exemplary in nature and are in no way intended to limit theinvention, its application, or uses. For example, other embodiments ofthe invention may use linearly moving strips or plates of MCE materialrather than rotating rings. Suitable linear motion may be continuous orreciprocating. As another example, yet other embodiments of theinvention may use electromagnets or superconducting magnets instead (orin a combination with) permanent magnets.

Apart for refrigeration and/or pumping heat, the MCR apparatus of thesubject invention may be also used to convert thermal energy intomechanical energy. Referring now to FIG. 2, the end cap 170 may bethermally connected to a suitable source of heat at a first temperatureand the end cap 168 may be thermally connected to a suitable heat sinkat a temperature substantially lower than the first temperature. Heatmay flow through the MCR 100 from the end cap 170 to the end cap 168 ina similar way as already described. Azimuthal temperature variations inthe MCE rings 162 may cause corresponding variations in themagnetization of the MCE material within the MCE rings 162. Inparticular, cooler portions of the MCE material may be magnetized moreand may be drawn more into the space between the magnets 146, which mayproduce a torque on the MCE ring 162, causing it to rotate the shaft158. MCR apparatus of the subject invention may be also used to convertlow-level heat into mechanical energy, which may make it useful forenergy recovery from waste heat generated by some combustion processes.Alternatively, the MCR apparatus of the subject invention may be used toconvert solar heat to a mechanical energy. In particular, the shaft 158may be coupled to an electric generator or a pump.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises”and/or “comprising,” and “includes” and/or “including” when used in thisspecification, specify the presence of stated features, integers, steps,operations, elements, and/or components, but do not preclude thepresence or addition of one or more other features, integers, steps,operations, elements, components, and/or groups thereof.

The terms of degree such as “substantially”, “about” and “approximately”as used herein mean a reasonable amount of deviation of the modifiedterm such that the end result is not significantly changed. For example,these terms can be construed as including a deviation of at least ±5% ofthe modified term if this deviation would not negate the meaning of theword it modifies.

The term “suitable,” as used herein, means having characteristics thatare sufficient to produce a desired result. Suitability for the intendedpurpose can be determined by one of ordinary skill in the art using onlyroutine experimentation.

Moreover, terms that are expressed as “means-plus function” in theclaims should include any structure that can be utilized to carry outthe function of that part of the present invention. In addition, theterm “configured” as used herein to describe a component, section orpart of a device includes hardware and/or software that is constructedand/or programmed to carry out the desired function.

Different aspects of the invention may be combined in any suitable way.

While only selected embodiments have been chosen to illustrate thepresent invention, it will be apparent to those skilled in the art fromthis disclosure that various changes and modifications can be madeherein without departing from the scope of the present invention asdefined in the appended claims. Furthermore, the foregoing descriptionof the embodiments according to the present invention are provided forillustration only, and not for the purpose of limiting the presentinvention as defined by the appended claims and their equivalents. Thus,the scope of the present invention is not limited to the disclosedembodiments.

What is claimed is:
 1. A magneto-caloric refrigerator (MCR) comprising:a magneto-caloric effect (MCE) material, a means for generating magneticfield, a first heat commutator, a second heat commutator, and a thermalinterface fluid (TIF); a) said MCE material being arranged to be inclose proximity to said first heat commutator thereby forming a firstgap therebetween; b) said MCE material being arranged to be in closeproximity to said second heat commutator thereby forming a second gaptherebetween; c) said TIF being arranged to substantially fill saidfirst gap and said second gap; d) said means for generating magneticfield arranged to produce a region of weak magnetic field and a regionof strong magnetic field; e) said first heat commutator comprising afirst thermally conducting core; f) said second heat commutatorcomprising a second thermally conducting core; g) said MCE materialbeing arranged to be in motion relative to each said first thermallyconducting core and said second thermally conducting core; h) saidmotion causing said MCE material to be alternately exposed to a weakmagnetic field and to a strong magnetic field; i) said MCE materialbeing arranged to be in good thermal communication with said firstthermally conducting core by means of said TIF when said MCE material isexposed to a weak magnetic field; and j) said MCE material beingarranged to be in good thermal communication with said second thermallyconducting core by means of said TIF when said MCE material is exposedto a strong magnetic field.
 2. The MCR of claim 1, wherein said motionis causing said TIF to flow in a shear flow regime.
 3. The MCR of claim1, wherein said first thermally conducting core is thermally coupled toa heat reservoir at a first temperature, said second thermallyconducting core is thermally coupled to a heat reservoir at a secondtemperature, and said second temperature is higher than said firsttemperature.
 4. The MCR of claim 1, wherein said TIF is selected fromthe family consisting of liquid metal, gallium-based liquid metal alloy,gallium-indium-tin liquid metal alloy, gallium-indium-tin-zinc liquidmetal alloy, nanofluid, and nanofluid substantially comprising carbonnanotubes.
 5. The MCR of claim 1, wherein said MCE material is formed asa disk arranged to rotate about its axis of rotational symmetry.
 6. TheMCR of claim 1, wherein said means for generating magnetic field isselected from the family consisting of a permanent magnet,electromagnet, and superconducting coil.
 7. The MCR of claim 1, whereinsaid first gap and said second gap are each selected to be between about50 and about 500 micrometers wide.
 8. A staged magnetocaloricrefrigerator (MCR) comprising a plurality of MCR stages; a) each saidMCR stage comprising a magnetocaloric effect (MCE) material, a firstthermally conducting core, a second thermally conducting core, a meansfor producing a region of strong magnetic field and a region of weakmagnetic field, and a thermal interface fluid (TIF); b) within each saidMCR stage, said first thermally conducting core of that MCR stage beingarranged to be in a good thermal communication by means of said TIF witha portion of said MCE material of that stage when said portion of saidMCE material of that stage is immersed in a weak magnetic field; c)within each said MCR stage, said second thermally conducting core ofthat MCR stage being arranged to be in a good thermal communication bymeans of said TIF with a portion of said MCE material of that MCR stagewhen said portion of said MCE material of that MCR stage is immersed ina strong magnetic field; d) the thermally conducting core of the firstMCR stage being thermally coupled to a lower heat reservoir; e) for eachsubsequent said MCR stage, the first thermally conducting core of thatMCR stage being coupled to the second thermally conducting core of thepreceding MCR stage; and f) said second thermally conducting core of thelast MCR stage being thermally coupled to an upper heat reservoir. 9.The staged MCR of claim 8, wherein the temperature of said lower heatreservoir is substantially lower than the temperature of said upper heatreservoir.
 10. The staged MCR of claim 8, wherein within each said MCRstage said MCE material of that MCR stage is arranged to be in motionrelative to each said first thermally conducting core of that MCR stageand said second thermally conducting core of that MCR stage.
 11. Thestaged MCR of claim 10, wherein said motion is causing said TIF to flowin a shear flow regime.
 12. The staged MCR of claim 8, wherein withineach said MCR stage, said first thermally conducting core of that MCRstage and said MCE material of that MCR stage are arranged to form afirst gap therebetween and said first gap is substantially filled withsaid TIF; and said second thermally conducting core of that MCR stageand said MCE material of that MCR stage are arranged to form a secondgap therebetween and said second gap is substantially filled with saidTIF.
 13. The staged MCR of claim 8, wherein said TIF has a thermalconductivity of at least 1 watt/meter—degree Kelvin.
 14. The staged MCRof claim 8, wherein said TIF is selected from the family consisting ofliquid metal, gallium-based liquid metal alloy, gallium-indium-tinliquid metal alloy, gallium-indium-tin-zinc liquid metal alloy,nanofluid, and nanofluid substantially comprising carbon nanotubes. 15.The staged MCR of claim 1, wherein said means for producing said regionof strong magnetic field is selected from the family consisting of apermanent magnet, electromagnet, and superconducting coil.
 16. Thestaged MCR of claim 1, wherein said thermal communication comprises aflow of heat through said TIF flowing in s shear flow regime.
 17. Amethod for pumping heat comprising the steps of: a) providing amagnetocaloric effect (MCE) material; b) providing a first thermalconductor at a first temperature; c) providing a second thermalconductor at a second temperature; d) arranging said MCE material to bein close proximity of said first conductor with a first gaptherebetween; e) arranging said MCE material to be in close proximity ofsaid second conductor with a second gap therebetween; f) substantiallyfilling said first gap and said second gap with a thermal interfacefluid (TIF); g) moving said MCE material with respect to said firstthermal conductor; h) moving said MCE material with respect to saidsecond thermal conductor; i) flowing said TIF in said first and saidsecond gap in a shear flow regime; j) exposing said MCE material to aweak magnetic field; k) forming a good thermal communication betweensaid MCE material and said first thermal conductor through said TIF; l)exposing said MCE material to a strong magnetic field; m) forming a goodthermal communication between said MCE material and said second thermalconductor through said TIF.
 18. The method of claim 17, wherein saidsecond temperature is higher than said first temperature.
 19. The methodof claim 17, wherein said steps of (j) exposing said MCE material to aweak magnetic field and (k) forming a good thermal communication betweensaid MCE material and said first thermal conductor through said TIF, areperformed concurrently.
 20. The method of claim 17, wherein said stepsof (l) exposing said MCE material to a strong magnetic field and (m)forming a good thermal communication between said MCE material and saidsecond thermal conductor through said TIF, are performed concurrently.